Hobart Welding Products 4500 Selecting Weld Cable Sizes, 150 ft 200 ft 250 ft, Connecting to weld

Page 24

5-7.

Selecting Weld Cable Sizes*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

 

 

 

 

 

 

 

 

 

 

 

 

Not Exceeding***

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100 ft (30 m) or Less

150 ft

200 ft

250 ft

300 ft

 

350 ft

400 ft

 

 

 

 

 

(45 m)

(60 m)

(70 m)

(90 m)

 

(105 m)

(120 m)

 

Weld Output

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Terminals

 

 

 

 

 

 

 

 

 

 

!

Turn off power before

Welding

10 − 60%

60 − 100%

 

 

 

 

 

 

 

 

connecting to weld

Duty

Duty

 

10 − 100% Duty Cycle

 

 

 

output terminals.

Amperes

 

 

 

 

Cycle

Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

!Do not use worn, dam- aged, undersized, or poorly spliced cables.

100

4 (20)

4 (20)

4 (20)

3 (30)

2 (35)

1 (50)

1/0 (60)

1/0 (60)

 

 

 

 

 

 

 

 

 

 

150

3 (30)

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

3/0 (95)

 

 

 

 

 

 

 

 

 

 

200

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

4/0 (120)

 

 

 

 

 

 

 

 

 

 

250

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0

2 ea. 2/0

(2x70)

(2x70)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

300

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0

2 ea. 3/0

2 ea. 3/0

(2x70)

(2x95)

(2x95)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm2 for metric useS-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

Notes

Work like a Pro!

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

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Contents OM-4418210 597K ProcessesDescription From Hobart to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peu- vent être dangereuxLE Soudage peut provoquer un incendie ou une explosion LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut Rendre Aveugle DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique LES Fils DE Soudage peuvent provoquer des blessures’EMPLOI Excessif peut UNE Remorque QUI Bascule peut entraîner des blessuresProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux− Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles Aux Power Gal./Hr Weld Power In KWFuel Consumption Weld Amps At Rated Duty CycleGenerator Power Curve AC Power VoltsAC Power Amperes Duty CycleVolt-Ampere Curves Volts Max Amp Min AmpAC Amps − Installation Installing Welding GeneratorRating Label Location MovementGrounding Generator When Supplying Building Systems Grounding Generator To Truck Or Trailer FrameEngine Prestart Checks 13 mm Full Gasoline Open/On Closed/OffOil Connecting To Weld Output Terminals Connecting to weld Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mMaterial Thickness Reference Chart − Operating the Welding Generator Controls See SectionTo Stop turn engine switch to Off Description Of Controls See SectionAmperage Selection Table For Stick Smaw Electrodes Generator Power Panel Receptacles − Operating Auxiliary EquipmentUse GFCI-protected extension cord X 15 a + 240 V x 9 a = 4 kVA/KW OM-4418− Maintenance Routine MaintenanceServicing Air Cleaner Stop engine− Troubleshooting TroubleshootingGenerator Power WeldingWith proper viscosity oil for operating temperature EngineStarting difficult − Electrical Diagrams Circuit Diagram For Welding Generator− Generator Power Guidelines Selecting EquipmentGrounding When Supplying Building Systems How Much Power Does Equipment Require?Use #10 AWG or larger insulated Resistive Load Volts 115 AmpsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure − Stick Welding Smaw GuidelinesElectrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Work like a Pro − Parts List Main AssemblySR1 Start Your Professional Welding Career Now Service SupportAssistance Contact your Distributor for Hobart Welding Products
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